Manufacturing method for lightweight large-size telescope mirror blanks and mirror blanks fabricated according to same

ABSTRACT

A method for manufacturing a mirror blank comprises: providing a primary piece of glass comprising a primary planar surface and a backing piece of glass comprising a backing planar surface; assembling a mirror blank assembly, wherein assembling the mirror blank assembly comprises interposing a plurality of glass splines between the primary glass and the backing glass. Interposing the plurality of glass splines comprises: for each glass spline, respectively abutting first and second opposed surfaces of the glass spline against the primary planar surface of the primary glass and against the backing planar surface of the backing glass. The mirror blank assembly is then heated to fuse the interposed glass splines to the primary glass and the backing glass while the primary glass and the secondary glass remain spaced apart from one another by the interposed glass splines to thereby provide the mirror blank.

RELATED APPLICATIONS

This application claims the benefit of the priority of U.S. application No. 62/055,592 filed 25 Sep. 2014, which is hereby incorporated herein by reference.

TECHNICAL FIELD

The invention relates to mirror blanks and their manufacture. Particular non-limiting embodiments provide lightweight large-size telescopic mirror blanks and methods of manufacturing the same.

BACKGROUND

Some optical instruments, such as telescopes and/or the like make use of large mirrors (e.g. 18″ and greater in diameter). Such large mirrors can be used at the primary (light gathering) mirrors of such optical instruments. Mirrors for optical instruments are typically formed by coating a reflective material (such as silver) onto a surface of a mirror blank typically fabricated from glass.

Traditionally, to provide sufficient structural rigidity, large mirror blanks (e.g. 18″ and greater in diameter) are made of a single solid piece of glass. The solid piece of glass is preheated until soft and then forged into the desired shape. After forging, the glass is cooled and drafted.

After cooling and drafting, there typically exists a large amount of residual stress within the glass that forms the blank. To reduce residual stress, the glass that forms the blank is typically annealed. Annealing involves controllably and slowly heating the glass to an annealing temperature, heat soaking the glass at the annealing temperature and then slowly and controllably decreasing the temperature of the glass. Annealing takes considerable time (e.g. hundreds of hours). It is not uncommon for the glass to crack during the heating and cooling processes associated with annealing.

To prevent optical distortion which may be caused, for example, by deformation of a solid glass mirror under its own weight, telescope frames have to be strong and rigid. This requirement raises the cost of manufacturing telescopes and leads to telescopes that are more difficult to assemble, disassemble and transport.

There is a general desire for improved mirror blanks and improved methods to manufacture mirror blanks.

The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.

SUMMARY OF THE INVENTION

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.

The invention comprises a number of non-limiting aspects. Non-limiting aspects of the invention comprise:

-   1. A method for manufacturing a mirror blank comprising:     -   providing a primary piece of glass comprising a primary planar         surface and a backing piece of glass comprising a backing planar         surface;     -   assembling a mirror blank assembly, wherein assembling the         mirror blank assembly comprises interposing a plurality of glass         splines between the primary glass and the backing glass, wherein         interposing the plurality of glass splines comprises:         -   for each glass spline, abutting a first surface of the glass             spline against the primary planar surface of the primary             glass and abutting a second surface of the glass spline, the             second surface opposed to the first surface, against the             backing planar surface of the backing glass; and         -   arranging the plurality of glass splines to be circularly             symmetric about an axis of symmetry that is orthogonal to             the primary planar surface and the backing planar surface             and to extend in directions that are radial from the axis of             symmetry;         -   wherein, for each glass spline, a dimension l₁ of the radial             extension of the first surface which abuts the primary             planar surface of the primary glass is greater than a             dimension l₂ of the radial extension of the second surface             which abuts the backing planar surface of the backing glass;             and     -   heating the mirror blank assembly to fuse the interposed glass         splines to the primary glass and the backing glass while the         primary glass and the secondary glass remain spaced apart from         one another by the interposed glass splines to thereby provide         the mirror blank. -   2. A method according to aspect 1 or any other aspect herein wherein     the primary glass, the backing glass and the glass splines have     thermal coefficients that are the same +/−5%. -   3. A method according to any one of aspects 1 to 2 or any other     aspect herein wherein the primary glass, the backing glass and the     glass splines have the same thermal coefficients. -   4. A method according to any one of aspects 1 to 3 or any other     aspect herein wherein the primary glass has a primary circular     perimeter having a primary diameter d₁ and the backing glass has a     backing circular perimeter having a backing diameter d₂ and d₁>d₂. -   5. A method according to aspect 4 or any other aspect herein     comprising aligning the primary glass and the backing glass so that     the axis of symmetry intersects the center of the primary circular     perimeter and the backing circular perimeter. -   6. A method according to any one of aspects 1 to 5 or any other     aspect herein wherein each of the glass splines has a first height     dimension x in a direction extending between the primary planar     surface and the backing planar surface at a side of the glass spline     closest to the axis of symmetry and a second height dimension y in     the direction extending between the primary planar surface and the     backing planar surface at a side of the glass spline most distal     from the axis of symmetry and where y<x. -   7. A method according to aspect 6 or any other aspect herein wherein     the primary glass has a primary circular perimeter having a primary     diameter d₁ and wherein, for each glass spline, the first height     dimension x is in a range between ½ to 1/20 of the primary diameter     d₁. -   8. A method according to any one of aspects 6 to 7 or any other     aspect herein wherein the primary glass has a primary circular     perimeter having a primary diameter d₁ and wherein, for each glass     spline, the first height dimension x is in a range between ⅙ to 1/10     of the primary diameter d₁. -   9. A method according to any one of aspects 1 to 8 or any other     aspect herein comprising shaping the primary glass to provide a     primary opening therethrough. -   10. A method according to aspect 9 or any other aspect herein     comprising locating the primary glass such that the axis of symmetry     extends through a center of the primary opening. -   11. A method according to any one of aspects 9 to 10 or any other     aspect herein comprising shaping the primary opening to have a     circular perimeter. -   12. A method according to any one of aspects 1 to 11 or any other     aspect herein comprising shaping the backing glass to provide a     backing opening therethrough. -   13. A method according to aspect 12 or any other aspect herein     comprising locating the backing glass such that the axis of symmetry     extends through a center of the backing opening. -   14. A method according to any one of aspects 12 to 13 or any other     aspect herein comprising shaping the backing opening to have a     circular perimeter. -   15. A method according to any one of aspects 1 to 14 or any other     aspect herein wherein interposing the plurality of glass splines     between the primary glass and the backing glass comprises spacing     the glass splines about the axis of symmetry with equal angular     spacing between circumferentially adjacent pairs of glass splines. -   16. A method according to any one of aspects 1 to 15 or any other     aspect herein wherein interposing the plurality of glass splines     between the primary glass and the backing glass comprises locating     the plurality of glass splines such that portions of     circumferentially adjacent glass splines closest to the axis of     symmetry contact one another at locations spaced apart from the axis     of symmetry. -   17. A method according to any one of aspects 1 to 16 or any other     aspect herein wherein interposing the plurality of glass splines     between the primary glass and the backing glass comprises locating     the plurality of glass splines such that portions of the glass     splines closest to the axis of symmetry are spaced apart from the     axis of symmetry and from one another. -   18. A method according to aspect 17 or any other aspect herein     wherein locating the plurality of glass splines such that the     portions of the glass splines closest to the axis of symmetry are     spaced apart from the axis of symmetry comprises locating the     plurality of glass splines such that the portions of the glass     splines closest to the axis of symmetry are spaced apart from the     axis of symmetry by a radial dimension that is the same for each     glass spline. -   19. A method according to any one of aspects 17 to 18 or any other     aspect herein wherein assembling the mirror blank assembly comprises     interposing a glass connector between the primary glass and the     backing glass, wherein interposing the glass connector between the     primary glass and the backing glass comprising abutting a first     surface of the glass connector against the primary planar surface of     the primary glass and abutting a second surface of the glass     connector against the backing planar surface of the backing glass     and wherein heating the mirror blank assembly comprises heating the     interposed glass connector and thereby fusing the glass connector to     the primary glass and the backing glass. -   20. A method according to aspect 19 or any other aspect herein     comprising shaping the glass connector to define a bore therethrough     and wherein interposing the glass connector between the primary     glass and the backing glass comprises extending at least a portion     of the bore between the primary planar surface of the primary glass     and the backing planar surface of the backing glass. -   21. A method according to aspect 20 or any other aspect herein     comprising shaping the glass connector to define at least a portion     of one or more venting apertures which permit fluid communication     between the bore of the glass connector and a region outside of the     bore of the glass connector when the glass connector is interposed     between the primary glass and the backing glass. -   22. A method according to aspect 21 or any other aspect herein     wherein the one or more venting apertures are defined in part by at     least one of the primary planar surface and the backing planar     surface. -   23. A method according to any one of aspects 19 to 22 or any other     aspect herein wherein the glass connector comprises a cylindrical     outer surface and wherein interposing the glass connector between     the primary glass and the backing glass comprises aligning the     cylindrical axis with the axis of symmetry and, for each glass     spline, abutting a surface of the glass spline closest to the axis     of symmetry against the cylindrical outer surface of the glass     connector. -   24. A method according to aspect 23 or any other aspect herein     wherein heating the interposed glass connector comprises fusing the     cylindrical outer surface of the glass connector to the glass     splines. -   25. A method according to any one of aspects 1 to 24 or any other     aspect herein wherein assembling the mirror blank assembly comprises     interposing a plurality of glass braces between the plurality of     glass splines, wherein interposing the plurality of glass braces     between the plurality of glass braces comprises, for each glass     brace, abutting opposing surfaces of the glass brace against each of     a corresponding pair of circumferentially adjacent glass splines. -   26. A method according to aspect 25 or any other aspect herein     wherein the glass braces are curved. -   27. A method according to aspect 25 or any other aspect herein     wherein the glass braces are generally straight and, for each glass     brace, the opposing surfaces of the glass brace are bevelled with     respect to the straight dimension of the glass brace. -   28. A method according to any one of aspects 25 to 27 or any other     aspect herein wherein heating the mirror blank assembly comprises     heating the interposed glass braces and thereby, for each glass     brace, fusing the opposing surfaces of the glass brace to the     corresponding pair of circumferentially adjacent glass splines. -   29. A method according to any one of aspects 25 to 28 or any other     aspect herein wherein heating the mirror blank assembly comprises,     for each glass brace, fusing the glass brace to the primary glass. -   30. A method according to any one of aspects 25 to 29 or any other     aspect herein wherein heating the mirror blank assembly comprises,     for each glass brace, fusing the glass brace to the backing glass. -   31. A method according to any one of aspects 1 to 30 or any other     aspect herein wherein providing the primary piece of glass comprises     abutting complementary surfaces of a pair of glass layers against     one another, at least one of the complementary surfaces of the pair     of glass layers comprising a plurality of channels, and wherein     heating the mirror blank assembly comprises heating the pair of     glass layers to fuse the complementary surfaces of the pair of glass     layers to one another. -   32. A method according to aspect 31 or any other aspect herein     wherein at least one of the plurality of channels extends between     peripheral edges of the at least one of the complementary surfaces     of the pair of glass layers. -   33. A method according to any one of aspects 1 to 32 or any other     aspect herein comprising, after heating the mirror blank assembly to     fuse the interposed glass splines to the primary glass and the     backing glass, cooling the mirror blank using a plurality of cooling     steps, the plurality of cooling steps comprising:     -   a first cooling step comprising allowing the mirror blank to         cool in a first environment until the mirror blank reaches a set         temperature; and     -   a second cooling step comprising allowing the mirror blank to         cool in a second environment until the mirror blank reaches an         ambient temperature;     -   wherein the first environment is regulated to have a decreasing         temperature and the second environment is regulated to have a         substantially constant temperature. -   34. A method according to any one of aspects 1 to 33 or any other     aspect herein wherein heating the mirror blank assembly to fuse the     interposed glass splines to the primary glass and the backing glass     comprises heating the mirror blank assembly to a temperature just     below their melting temperature and heat-soaking the primary glass,     the backing glass and the interposed glass splines at this     temperature. -   35. A method according to any one of aspects 1 to 34 or any other     aspect herein wherein heating the mirror blank assembly to fuse the     interposed glass splines to the primary glass and the backing glass     comprises, for each glass spline, fusing the first surface of the     glass spline to the primary planar surface of the primary glass and     fusing the second surface of the glass spline to the backing planar     surface of the backing glass. -   36. A method according to any one of aspects 1 to 35 or any other     aspect herein wherein heating the mirror blank assembly to fuse the     interposed glass splines to the primary glass and the backing glass     comprises allowing the weight of at least one of primary glass, the     backing glass and the interposed glass splines to assist with the     fusing the of the interposed glass splines to the primary glass and     the backing glass. -   37. A mirror blank fabricated according to the method of any one of     aspects 1 to 36. -   38. A monolithic glass mirror blank comprising:     -   a primary portion and a backing portion spaced apart from one         another;     -   a plurality of spline portions extending between the primary         portion and the backing portion;     -   wherein, for each spline portion, a first surface of the spline         portion is fused to the primary portion and a second surface of         the spline portion, the second surface opposed to the first         surface, is fused to the backing portion;     -   wherein the plurality of spline portions are arranged to be         circularly symmetric about an axis of symmetry and to extend in         directions that are radial from the axis of symmetry; and     -   wherein, for each spline portion, a dimension l₁ of the radial         extension of the first surface which abuts the primary portion         is greater than a dimension l₂ of the radial extension of the         second surface which abuts the backing portion. -   39. A mirror blank according to aspect 38 or any other aspect herein     wherein the primary portion, the backing portion and the splines     portions have thermal coefficients that are the same +/−5%. -   40. A mirror blank according to any one of aspects 38 to 39 or any     other aspect herein wherein the primary portion, the backing portion     and the spline portions have the same thermal coefficients. -   41. A mirror blank according to any one of aspects 38 to 40 or any     other aspect herein wherein the primary portion has a primary     circular perimeter having a primary diameter d₁ and the backing     portion has a backing circular perimeter having a backing diameter     d₂ and d₁>d₂. -   42. A mirror blank according to aspect 41 or any other aspect herein     wherein the primary portion and the backing portion are aligned so     that the axis of symmetry intersects the center of the primary     circular perimeter and the backing circular perimeter. -   43. A mirror blank according to any one or aspects 38 to 41 or any     other aspect herein wherein each of the spline portions has a first     height dimension x in a direction extending between the primary     portion and the backing portion at a side of the spline portion     closest to the axis of symmetry and a second height dimension y in     the direction extending between the primary portion and the backing     portion at a side of the spline portion most distal from the axis of     symmetry and where y<x. -   44. A mirror blank according to aspect 43 or any other aspect herein     wherein the primary portion has a primary circular perimeter having     a primary diameter d₁ and wherein, for each spline portion, the     first height dimension x is in a range between ½ to 1/20 of the     primary diameter d₁. -   45. A mirror blank according to any one of aspects 43 to 44 or any     other aspect herein wherein the primary portion has a primary     circular perimeter having a primary diameter d₁ and wherein, for     each spline portion, the first height dimension x is in a range     between ⅙ to 1/10 of the primary diameter d₁. -   46. A mirror blank according to any one of aspects 38 to 45 or any     other aspect herein wherein the primary portion is shaped to provide     a primary opening therethrough. -   47. A mirror blank according to aspect 46 or any other aspect herein     wherein the primary portion is aligned such that the axis of     symmetry extends through a center of the primary opening. -   48. A mirror blank according to any one of aspects 46 to 47 or any     other aspect herein wherein the primary opening has a circular     perimeter. -   49. A mirror blank according to any one of aspects 38 to 48 or any     other aspect herein wherein the backing portion is shaped to provide     a backing opening therethrough. -   50. A mirror blank according to aspect 49 or any other aspect herein     wherein the backing portion is aligned such that the axis of     symmetry extends through a center of the backing opening. -   51. A mirror blank according to any one of aspects 49 to 50 or any     other aspect herein wherein the backing opening has a circular     perimeter. -   52. A mirror blank according to any one of aspects 38 to 51 or any     other aspect herein wherein the glass spline portions are arranged     about the axis of symmetry to have equal angular spacing between     circumferentially adjacent pairs of spline portions. -   53. A mirror blank according to any one of aspects 38 to 52 or any     other aspect herein wherein the plurality of spline portions are     located such that portions of circumferentially adjacent spline     portions closest to the axis of symmetry contact one another at     locations spaced apart from the axis of symmetry. -   54. A mirror blank according to any one of aspects 38 to 53 or any     other aspect herein wherein the plurality of spline portions are     located such that portions of the spline portions closest to the     axis of symmetry are spaced apart from the axis of symmetry and from     one another. -   55. A mirror blank according to aspect 54 or any other aspect herein     wherein the plurality of spline portions are located such that the     portions of the spline portions closest to the axis of symmetry are     spaced apart from the axis of symmetry by a radial dimension that is     the same for each spline portion. -   56. A mirror blank according to any one of aspects 54 to 55 or any     other aspect herein comprising a connector portion between the     primary portion and the backing portion, a first surface of the     connector portion fused to the primary portion and a second surface     of the connector portion fused to the backing portion. -   57. A mirror blank according to aspect 56 or any other aspect herein     wherein the connector portion is shaped to define a bore     therethrough and at least a portion of the bore extends between the     primary portion and the backing portion. -   58. A mirror blank according to aspect 57 or any other aspect herein     wherein the connector portion is shaped to define at least a portion     of one or more venting apertures which permit fluid communication     between the bore of the connector portion and a region outside of     the bore of the connector portion. -   59. A mirror blank according to aspect 58 or any other aspect herein     wherein the one or more venting apertures are defined in part by at     least one of the primary portion and the backing portion. -   60. A mirror blank according to any one of aspects 56 to 59 or any     other aspect herein wherein the connector portion comprises a     cylindrical outer surface having a cylindrical axis aligned with the     axis of symmetry and, for each spline portion, a surface of the     spline portion closest to the axis of symmetry is fused to the     cylindrical outer surface of the connector portion. -   61. A mirror blank according to any one of aspects 38 to 60 or any     other aspect herein comprising a plurality of brace portions     interposed between the plurality of spline portions, wherein, for     each glass brace, opposing surfaces of the glass brace are fused to     each of a corresponding pair of circumferentially adjacent glass     splines. -   62. A mirror blank according to aspect 61 or any other aspect herein     wherein the brace portions are curved. -   63. A mirror blank according to aspect 61 or any other aspect herein     wherein the brace portions are generally straight and, for each     brace portion, the opposing surfaces of the brace portion are     bevelled with respect to the straight dimension of the brace     portion. -   64. A mirror blank according to any one of aspects 61 to 63 or any     other aspect herein wherein each brace portion is fused to the     primary portion. -   65. A mirror blank according to any one of aspects 61 to 64 or any     other aspect herein wherein each brace portion is fused to the     backing portion. -   66. A mirror blank according to any one of aspects 38 to 65 or any     other aspect herein wherein the primary portion comprises a pair of     glass layers having complementary surfaces fused to one another, at     least one of the complementary surfaces comprising a plurality of     channels. -   67. A mirror blank according to aspect 66 or any other aspect herein     wherein at least one of the plurality of channels extends between     peripheral edges of the at least one of the complementary surfaces     of the pair of glass layers. -   68. A method for manufacturing a mirror blank assembly comprising:     -   providing a primary piece of glass comprising a primary planar         surface and a backing piece of glass comprising a backing planar         surface; and     -   assembling a mirror blank assembly, wherein assembling the         mirror blank assembly comprises interposing a plurality of glass         splines between the primary glass and the backing glass, wherein         interposing the plurality of glass splines comprises:         -   for each glass spline, abutting a first surface of the glass             spline against the primary planar surface of the primary             glass and abutting a second surface of the glass spline, the             second surface opposed to the first surface, against the             backing planar surface of the backing glass; and         -   arranging the plurality of glass splines to be circularly             symmetric about an axis of symmetry that is orthogonal to             the primary planar surface and the backing planar surface             and to extend in directions that are radial from the axis of             symmetry; and         -   wherein, for each glass spline, a dimension l₁ of the radial             extension of the first surface which abuts the primary             planar surface of the primary glass is greater than a             dimension l₂ of the radial extension of the second surface             which abuts the backing planar surface of the backing glass. -   69. A method for assembling a mirror blank assembly comprising any     of the steps of aspects 1 to 37. -   70. A mirror blank assembly assembled according to any one of the     methods of aspects 68 to 69. -   71. Methods comprising any features, combinations of features and/or     sub-combinations of features disclosed herein. -   72. Apparatus comprising any features, combinations of features     and/or sub-combinations of features disclosed herein.

In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.

FIG. 1 depicts a mirror blank assembly according to a particular embodiment.

FIG. 2 depicts the primary glass of the FIG. 1 mirror blank assembly.

FIG. 3 depicts the backing glass of the FIG. 1 mirror blank assembly.

FIG. 4 depicts a glass spline of the FIG. 1 mirror blank assembly.

FIG. 5 depicts a mirror blank assembly according to another embodiment.

FIG. 6 depicts a mirror blank assembly according to another embodiment.

FIG. 7 depicts an exploded view of either of the FIG. 5 or FIG. 6 mirror blank assemblies.

FIG. 8 depicts a mirror blank assembly according to another embodiment.

FIG. 9 depicts an exploded view of the FIG. 8 mirror blank assembly.

FIG. 10 depicts a mirror blank assembly according to another embodiment.

FIG. 11 depicts an exploded view of the FIG. 10 mirror blank assembly.

FIG. 12 depicts a connector which may be used with the FIG. 10 mirror blank assembly or any of the other mirror blank assemblies described herein.

FIG. 13 depicts a mirror blank assembly according to another embodiment.

FIG. 14 depicts a mirror blank assembly according to another embodiment.

FIG. 15 depicts a pair of glass layers used to provide a primary glass according to a particular embodiment.

FIG. 16 depicts an exploded view of the FIG. 15 pair of glass layers.

FIG. 17 depicts a magnified partial view of a surface of one of the FIG. 15 pair of glass layers.

FIG. 18 depicts a spherically convex mold according to a particular embodiment.

DESCRIPTION

Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

Aspects of the invention provide mirror blank assemblies. In some embodiments, the mirror blank assembly is large (e.g. 18″ and greater in diameter) and lightweight. In some embodiments, a mirror blank assembly comprises a plurality of separate components which are assembled relative to one another but which are not yet fused or otherwise attached to one another. A mirror blank assembly may be assembled as a part of a method for manufacturing a mirror blank. Aspects of the invention provide methods for manufacturing a mirror blank which comprise assembling a mirror blank assembly and then heating the mirror bank assembly to fuse its components to one another and to thereby provide a monolithic (i.e. one piece) mirror blank. Aspects of the invention provide mirror blanks manufactured by such methods.

FIG. 1 depicts a mirror blank assembly 10 according to a particular embodiment. Mirror blank assembly 10 of the FIG. 1 embodiment comprises a primary piece of glass 12 (which may be referred to herein as primary glass 12), a backing piece of glass 14 (which may be referred to herein as backing glass 12) and a plurality of glass splines 16 which may be interposed between primary glass 12 and backing glass 14.

As shown in FIG. 2, primary glass 12 comprises a primary planar (e.g. flat) surface 12 b. Grinding, polishing, molding or otherwise making planar surface 12 b relatively smooth (e.g. relatively free from bumps or indentations) may help to avoid the formation of bubbles between primary planar surface 12 b and abutting surfaces (e.g. abutment surfaces 16 a) of glass splines 16 during heating (as described below). In the illustrated embodiment of FIG. 2, primary glass 12 is generally disc-shaped with a generally planar opposing surface 12 c (i.e. opposed to primary planar surface 12 b), a circular perimeter with a diameter d₁ and a circumferential edge 12 a. Circumferential edge 12 a may extend between primary planar surface 12 b and opposing surface 12 c with a uniform thickness t₁ and may be oriented orthogonally to both primary planar surface 12 b and opposing surface 12 c. The thickness t₁ of primary glass 12 may depend on the diameter d₁ of primary glass 12 (e.g. a greater thickness t₁ may be desirable to support a greater diameter d₁), but is not necessarily so. In some embodiments, primary glass 12 may have other shapes. By way of non-limiting example: opposing surface 12 c need not be flat or planar and may have other surface shapes; the perimeter shape of primary glass 12 may be other than circular; circumferential edge 12 a may be angled, beveled or rounded; the thickness t₁ may vary around the perimeter of primary glass 12; and/or the like.

Backing glass 14 is shown best in FIG. 3. In the illustrated embodiment, backing glass 14 is generally disc-shaped with a generally planar opposing surface 14 c (i.e. opposed to backing planar surface 14 b), a circular perimeter with a diameter d₂ and a circumferential edge 14 a. Circumferential edge 14 a may extend between backing planar surface 14 b and opposing surface 14 c with a uniform thickness t₂ and may be oriented orthogonally to both backing planar surface 14 b and opposing surface 14 c. The thickness t₂ of backing glass 14 may depend on the diameter d₂ of backing glass 14 (e.g. a greater thickness t₂ may be desirable to support a greater diameter d₂), but is not necessarily so. In some embodiments, backing glass 14 may have other shapes. By way of non-limiting example: opposing surface 14 c need not be flat or planar and may have other surface shapes; the perimeter shape of backing glass 14 may be other than circular; circumferential edge 14 a may be angled, beveled or rounded; the thickness t₂ may vary around the perimeter of backing glass 14; and/or the like.

In some embodiments, such as the illustrated embodiment, the diameter d₂ of backing glass 14 is smaller than the diameter d₁ of primary glass 12 (i.e. d₂<d₁). In some embodiments, diameter d₂ is approximately half of diameter d₁.

As depicted in FIG. 1, mirror blank assembly 10 comprises a plurality of glass splines 16. The number of glass splines 16 can vary for different embodiments. In some cases, as the diameter of mirror blank assembly 10 (e.g. the diameter d₁ of primary glass 12 and/or the diameter d₂ of backing glass 14) increases, it may be beneficial to increase the number of glass splines 16. In particular, some embodiments comprise between 3 and 20 glass splines 16; and some embodiment comprise between 8 and 16 glass splines. FIG. 1 depicts an embodiment having 12 glass splines 16. In the illustrated embodiment, glass splines 16 all have substantially the same size and shape, although this is not necessary. In some embodiments, some glass splines 16 may have different sizes and/or shapes that other glass splines 16.

Glass splines 16 of the FIG. 1 mirror blank assembly 10 are shown best in FIG. 4. Glass spline 16 of the FIG. 3 embodiment comprises a substantially planar (e.g. flat) abutment surface 16 a which (as explained in more detail below) may abut against primary planar surface 12 b of primary glass 12 in mirror blank assembly 10. Opposing sides 16 b and 16 c extend from opposing ends of abutment surface 16 a. Abutment surface 16 a may have a dimension l₁ between opposing sides 16 b, 16 c. In some embodiments, opposing sides 16 b and 16 c extend parallel to each other and generally orthogonally to abutment surface 16 a. In other embodiments, opposing sides 16 b and 16 c may extend in different directions (e.g. at different angles) from one another and/or relative to abutment surface 16 a. In the illustrated embodiment, side 16 b has dimension x (in a direction orthogonal from planar abutment surface 16 a) and side 16 c has dimension y (in the direction orthogonal to planar abutment surface 16 a). Without loss of generality, these dimensions x, y may be referred to herein as height dimensions, it being understood that unless the context dictates otherwise the word height is merely a convenient label for these dimensions to distinguish them from other dimensions of interest. Glass spline 16 of the illustrated embodiment also comprises a substantially planar (e.g. flat) opposing abutment surface 16 d. Opposing abutment surface 16 d extends, generally parallel and opposite to abutment surface 16 a, from side 16 b toward side 16 c. Opposing abutment surface may have a dimension l₂ in a direction aligned with dimension l₁ of abutment surface 16 a. In the illustrated embodiment, y<x and l₂<l₁. In embodiments where l₂<l₁, glass spline 16 may comprise an additional surface 16 e which extends from opposing abutment surface 16 d to side 16 c. In some embodiments, it is possible to have l₂<l₁ because the diameter d₂ of backing glass 14 (and its planar backing surface 14 b) is less than the diameter d₁ of primary glass 12 (and its planar primary surface 12 b). Having l₂<l₁ and/or d₂<d₁ advantageously reduces the weight of mirror blank assembly 10 and mirror blanks formed therefrom. However, providing l₂<l₁ is not necessary. In some embodiments, height x is equal to height y, opposing abutment surface 16 d extends all the way from side 16 b to side 16 c and the dimensions l₁=l₂. Where the dimensions x=y and l₁=l₂, glass spline 16 is a rectangular prism. In some embodiments, height x is approximately ½ to 1/20 of diameter d₁ of primary glass 12. In other embodiments, height x is ⅙ to 1/10 of diameter d₁ of primary glass 12.

As depicted in FIG. 1, mirror blank assembly 10 may be assembled by interposing glass splines 16 between primary glass 12 and backing glass 14. Interposing glass splines 16 between primary glass 12 and backing glass 14 may comprise respectively abutting abutment surfaces 16 a, 16 d of glass splines 16 against planar surfaces 12 b, 14 b of primary glass 12 and backing glass 14. In this manner, glass splines 16 may support backing glass 14 relative to primary glass 16 (or vice versa) and may maintain the spaced apart relationship between backing glass 14 and primary glass 16. In mirror blank assembly 10 of the FIG. 1 embodiment, respective planar surfaces 12 b, 14 b are facing one another, parallel to one another and spaced apart from one another.

Mirror blank assembly 10 of the FIG. 1 embodiment is circularly symmetric about an axis of symmetry 20. Axis of symmetry 20 may be orthogonal to planar surfaces 12 b, 14 b of primary glass 12 and secondary glass 14, although this is not necessary. Axis of symmetry 20 may extend through a center of primary glass 12 and a center of backing glass 14 (e.g. through the centers of their respective circular perimeters), although this is not necessary. In some embodiments, glass splines 16 may be arranged relative to each other and/or relative to primary glass 12 and backing glass 14, such that glass splines 16 are circularly symmetric about symmetry axis 20. In some embodiments, glass splines 16 are arranged to extend in radial directions from symmetry axis 20 (although, as shown in FIG. 1, each glass spline 16 need not extend all the way to symmetry axis 20). In some embodiments, glass splines 16 are arranged to extend in radial directions which extend between a circular perimeter of primary glass 12 and symmetry axis 20. In some embodiments, each pair of adjacent (e.g. circumferentially adjacent) glass splines 16 may be angularly spaced apart from one another. In some embodiments, each pair of adjacent glass splines 16 may have at least approximately equal angular spacing.

In the FIG. 1 embodiment, glass splines 16 are interposed between primary glass 12 and backing glass 14 such that the portions of circumferentially adjacent glass splines 16 closest to symmetry axis 20 (e.g. the edges of sides 16 b) contact one another. These portions of circumferentially adjacent glass splines 16 closest to symmetry axis 20 may contact one another at locations that are spaced apart from symmetry axis 20. This contact between circumferentially adjacent glass splines 16 is not necessary. In some embodiments, glass splines 16 are located such that the portions of the glass splines 16 closest to symmetry axis 20 are spaced apart from symmetry axis 20 and/or from one another. In some embodiments, the portions of glass splines that are closest to symmetry axis 20 may be spaced apart from symmetry axis 20 by a radial dimension that is the same for each glass spline 16.

In mirror blank assembly 10 of the FIG. 1 embodiment, backing glass 14 is generally spaced apart from primary glass 12 by interposed glass splines 16 by a distance x, equal to the height of side 16 b which is closest to the axis of symmetry or equal to the space between parallel abutment surfaces 16 a, 16 d of glass splines 16. Backing glass 14 may overhang planar surfaces 16 d of glass splines 16, may be aligned with the outer ends of planar surfaces 16 d (as is the case in the FIG. 1 embodiment) or may not reach the radially outer edges of abutment surfaces 16 d.

FIG. 5 depict a mirror blank assembly 110 according to a particular embodiment. FIG. 6 depicts a mirror blank assembly 110′ according to a particular embodiment. FIG. 7 depicts an exploded view of either of mirror blanks 110, 110′. Mirror blank assemblies 110, 110′ are generally similar to mirror blank assembly 10 described elsewhere herein and similar reference numerals are used to describe features of mirror blank assemblies 110, 110′ which are similar to those of mirror blank assembly 10, except that the reference numerals for mirror blank assemblies 110, 110′ are preceded with the digit “1”. Mirror blank assemblies 110, 110′ differ primarily from mirror blank assembly 10 in that backing glass 114 of both mirror blank assemblies 110, 110′ is shaped to define a backing opening 114 d. In some embodiments, backing opening 114 d has a circular perimeter. In other embodiments, backing opening 114 d may have a differently shaped perimeter. Backing opening 114 d may be shaped and/or located, such that symmetry axis 120 passes through a center of backing opening 114 d. Backing opening 114 d may be of any diameter that allows for a sufficient amount of contact between abutment surfaces 116 d of each of the plurality of glass splines 116 and planar surface 114 b of backing glass 114. Backing opening 114 d reduces the weight of mirror blank assemblies 110, 110′ and provides a fluid communication channel which may provide ventilation and/or improve heat transfer during the heating of mirror blank assemblies 110, 110′.

The components of mirror blank assemblies 110, 110′ (e.g. primary glass 112, backing glass 114 and glass splines 116) are substantially similar to one another. Mirror blanks 110, 110′ differ from one another primarily in that, when interposed between primary glass 112 and backing glass 114, glass splines 116 of mirror blank assembly 110 (FIG. 5) are located such that the portions of glass splines 116 closest to axis of symmetry 120 are spaced apart from one another, whereas glass splines 116 of mirror blank assembly 110′ (FIG. 6) are located such that the portions of glass splines 116 closest to axis of symmetry 120 contact their circumferentially adjacent splines 116. In both the cases of mirror blank assembly 110 and mirror blank assembly 110′, the portions of glass splines 116 closest to axis of symmetry 120 are located at a generally constant radial distance from axis of symmetry 120.

FIGS. 8 and 9 depict mirror blank assembly 210 according to a particular embodiment. Mirror blank assembly 210 is generally similar to mirror blank assemblies 10, 110, 110′ described elsewhere herein and similar reference numerals are used to describe features of mirror blank assembly 210 which are similar to those of mirror blank assemblies 10, 110, 110′, except that the reference numerals for mirror blank assembly 210 are preceded with the digit “2”. Mirror blank assembly 210 differs from mirror blank assembly 110′ in that primary glass 212 is shaped to define primary opening 212 d. In some embodiments, primary opening 212 d has a circular perimeter. In other embodiments, primary opening 212 d may have a differently shaped perimeter. Primary opening 212 d may be shaped and/or located, such that symmetry axis 220 passes through a center of primary opening 212 d. Primary opening 212 d may be of any diameter that allows for a sufficient amount of contact between abutment surfaces 216 d of each of the plurality of glass splines 216 and planar surface 214 b of backing glass 214 while meeting any requirements of an optical instrument for which mirror blank assembly 210 is being made. Primary opening 214 d reduces the weight of mirror blank assembly 210 and provides a fluid communication channel which may provide ventilation and/or improve heat transfer during the heating of mirror blank assembly 210.

Like mirror blank assemblies 110, 110′, mirror blank assembly 210 of the illustrated embodiment, comprises backing glass 214 shaped to define backing opening 214 d which may comprise features substantially similar to backing opening 114 d of mirror blank assemblies 110, 110′ described elsewhere herein. However, backing opening 214 d is not necessary and, in some embodiments, mirror blank assembly 210 may be provided without backing opening 214 d. In the illustrated embodiment, mirror blank assembly 210 has its glass splines 216 located so that the portions of glass splines closest to symmetry axis 220 contact one another (in a manner similar to that of mirror blank assembly 110′ (FIG. 6). This is not necessary. In some embodiments, mirror blank assembly 210 may be assembled such that its glass splines 216 are located such that the portions of glass splines 216 located closest to symmetry axis 220 are spaced apart from one another (in a manner similar to that of mirror blank assembly 110 (FIG. 5)).

FIGS. 10 and 11 depict mirror blank assembly 310 according to a particular embodiment. Mirror blank assembly 310 is generally similar to mirror blank assemblies 10, 110, 110′, 210 described elsewhere herein and similar reference numerals are used to describe features of mirror blank assembly 310 which are similar to those of mirror blank assemblies 10, 110, 110′, 210, except that the reference numerals for mirror blank assembly 310 are preceded with the digit “3”. Mirror blank assembly 310 differs from mirror blank assembly 210 in that mirror blank assembly comprises a connector 318 (e.g. a generally tubular connector 318) which is interposed between primary glass 312 and backing glass 314. Interposing connector 318 between primary glass 312 and backing glass 314 may comprise abutting first and second opposed abutment surfaces 318 b, 318 c against planar surfaces 312 b, 314 b of primary glass 312 and backing glass 314. In the illustrated embodiment, connector 318 comprises a cylindrical outer surface 318 a. In some embodiments, the cylindrical outer surface 318 a of connector 318 may have a cylindrical axis that is co-axial with (or otherwise aligned with) axis of symmetry 320. In the illustrated embodiment, connector 318 is shaped to define a bore 318 d that extends therethrough. In some embodiments, at least a portion of bore 318 d extends between the planar surfaces 312 b, 314 b of primary glass 312 and backing glass 314. In the FIG. 10 embodiment, portions of glass splines 316 closest to symmetry axis 320 (e.g. sides 316 b) abut against outer surface 318 a of connector 318. This is not necessary. In some embodiments, glass splines 316 may be located to be spaced apart from connector 318. Connector 318 may provide additional strength to mirror blank assembly 310 by providing increased surface area in the connections between primary glass 312, glass splines 16 and backing glass 314.

Like mirror blank assembly 210, mirror blank assembly 310 of the illustrated embodiment, comprises backing glass 314 shaped to define backing opening 314 d and primary glass 312 shaped to define primary opening 312 d. The features of backing opening 314 d and primary opening 312 d may be substantially similar to backing opening 214 d and primary opening 214 d of mirror blank assembly 210 described elsewhere herein. However, neither backing opening 314 d nor primary opening 312 d is necessary. In some embodiments, mirror blank assembly 310 may be provided without backing opening 314 d and/or without primary opening 312 d.

In some embodiments of mirror blank assembly 310, especially where primary glass 312 does not include a primary opening 312 d and/or backing glass 314 does not include a backing opening 314 d, a modified connector 322 may replace connector 318. Connector 322, as depicted in FIG. 12, includes one or more venting aperture 322 e to allow fluid communication between bore 322 d and a region outside of bore 322 d when connector 322 is interposed between primary glass 312 and backing glass 314. In the illustrated embodiment, venting apertures are defined in part by the concave feature 322 e in connector 322 and in part by one or both of planar surfaces 312 b, 314 b. This is not necessary. In some embodiments, venting apertures may be additionally or alternatively defined completely by connector 322. Connector 322 of the FIG. 12 embodiment may be used even in embodiments, where mirror blank assembly 310 include primary opening 312 d or backing opening 314 d (such as in the illustrated embodiment of FIGS. 10 and 11).

FIGS. 13 and 14 depict schematic views of mirror blank assemblies 410, 410′ according to particular embodiments. Mirror blank assemblies 410, 410′ are generally similar to mirror blank assemblies 10, 110, 110′, 210, 310 described elsewhere herein and similar reference numerals are used to describe features of mirror blank assemblies 410, 410′ which are similar to those of mirror blank assemblies 10, 110, 110′, 210, 310, except that the reference numerals for mirror blank assemblies 410, 410′ are preceded with the digit “4”. Mirror blank assemblies 410, 410′ differ from mirror blank assemblies 10, 110, 110′, 210, 310 primarily in that mirror blank assemblies 410, 410′ respectively comprise glass braces 422, 422′ interposed between and abutting against circumferentially adjacent pairs of glass splines 416. In the illustrated embodiment, glass braces 422, 422′ are arranged to abut against each circumferentially adjacent pair of glass splines 416, although this is not necessary and, in some embodiments, glass braces 422, 422′ could be arranged to abut against one or more selected pairs of circumferentially adjacent glass splines 416.

Glass braces 422, 422′ may be straight (having a pair of opposed planar surfaces) with opposing edge surfaces that are beveled with respect to the planar surfaces, for abutting circumferentially adjacent glass splines 16. Additionally or alternatively, glass braces 422, 422′ may be curved with opposing edge surfaces that are beveled or non-beveled for abutting against circumferentially adjacent glass splines 416, as illustrated in FIG. 13. Glass braces 422, 422′ may be interposed between primary glass 412 and backing glass 414. Glass braces 422, 422′ may abut either or both of primary planar surface 412 b and backing planar surface 414 c, although this is not necessary. Glass braces 422′ may be arranged relatively close to axis of symmetry 420 to space apart circumferentially adjacent glass splines 16, as illustrated in FIG. 14. Since glass braces 422′ are located within a distance d₂/2 from axis of symmetry 420, glass braces 422′ may abut against (and be subsequently fused to) the planar surfaces 412 b, 414 b of both primary glass 412 and backing glass 414. Glass braces 422 may additionally or alternatively be arranged further from axis of symmetry 420, as illustrated in FIG. 13. Since braces 422 are located at distances greater than d₂/2 from axis of symmetry 420, braces 422 may abut against (and be subsequently fused to) only the planar surface 412 b of primary glass 412. In some embodiments, glass braces 422, 422′ may include venting notches (e.g. similar to notch 322 e of connector 322), apertures or the like for allowing air to escape from the center of mirror blank assembly 410. In some embodiments of mirror blank assembly 410, different glass braces 422, 422′ may be located at different radial distances from the axis of symmetry. In others, all glass braces 422, 422′ may be equidistant from the axis 420 of mirror blank assembly 410.

In some situations, primary glass 12 may only be conveniently available (e.g. to fabricate, to transport and/or to purchase) in a limited variety of thicknesses. To achieve a desired thickness t₁, two or more layers 512 d, 512 e of primary glass may be joined together as illustrated in FIGS. 15 and 16 to form primary glass 512. For example, if primary glass layers 512 d, 512 e are only conveniently available with thicknesses of 6 mm and 8 mm, while the desired thickness of primary glass 512 is 14 mm, one 6 mm layer 512 d can be fused to one 8 mm layer 512 e.

Layers 512 d and 512 e may be fused by abutting their complementary surfaces 513 d, 513 e together and then applying heat to fuse layers 512 d, 512 e. In some embodiments, where layers 512 d, 512 e are part of a glass blank assembly, layers 512 d, 512 e may be heated and fused in the same step as the rest of the glass blank assembly. In other embodiments, layers 512 d, 512 e may be fused in a separate step. In the illustrated embodiment, complementary surfaces 513 d, 513 e of layers 512 d, 512 e are generally planar (e.g. flat), although this is not necessary. During the heating process, air bubbles may form between layers 512 d, 512 e (e.g. due to air trapped by the imperfections in the smoothness of complementary surfaces 513 d, 513 e. Such air bubbles may detrimentally impact the strength, hardness, shape and other properties of primary glass 512. To minimize the likelihood of air bubbles forming, complementary surfaces 513 d, 513 e of one or both of layers 512 d, 512 e may include one or more channels or grooves 512 f for allowing air to escape from between layers 512 d, 512 e. In the illustrated embodiment of FIGS. 15-17, such channels 512 f are provided complementary surface 513 d of layer 512 d. Channels 512 f may comprise concavities in their corresponding complementary surface (e.g. in complementary surface 513 d in the case of the illustrated embodiment). Channels 512 f may comprise concavities that open toward the other layer (e.g. toward layer 512 e in the case of the illustrated embodiment). In some embodiments, channels 512 f are organized in a grid pattern with rows arranged perpendicular to columns, wherein the rows and columns extend to a peripheral edge of their respective complementary surface (e.g. to the peripheral edge of complementary surface 513 d in the case of the illustrated embodiment). In some embodiments, channels 512 f may be arranged in any pattern suitable for allowing air to escape to the circumferential edges of the primary glass 512.

Channels 512 f may take any cross-sectional shape. In some embodiments, channels 512 f are square in cross-section while in other embodiments, channels 512 f are rounded in cross-section such as depicted in FIG. 17.

The components of mirror blank assemblies according to various embodiments (e.g. primary glass 12, backing glass 14, glass splines 16, connectors 318 and 320 and glass braces 422) may be made of the same type of glass or a variety of types of glass as long, as the various components can be fused together. In currently preferred embodiments, the glass used to fabricate the components of mirror blank assemblies have the same or similar thermal expansion coefficients. In particular, in some embodiments, primary glass 12, backing glass 14, glass splines 16, connectors 318 and 320 and glass braces 422 may have thermal expansion coefficients within +/−5% of each other. In some embodiments, these thermal expansion coefficients are within +1-15% of each other. In some embodiments, these thermal expansion coefficients are within +/−1% of each other. In some embodiments, glass 12, backing glass 14, glass splines 16, connectors 318 and 320 and glass braces 422 have the same thermal expansion coefficients.

An aspect of the invention provides methods for manufacturing mirror blanks. In some embodiments, the method is for manufacturing large (e.g. 18″ and greater in diameter), lightweight mirror blanks.

In some embodiments, a first step is to assemble a mirror blank assembly. A mirror blank assembly may comprise a plurality of components as described above in relation to mirror blank assemblies 10, 110, 210, 310 and 410. The following method may be practiced with any of the mirror blank assemblies described above or any variation of the mirror blank assemblies comprising a combination of the features described above.

After a mirror blank assembly (10, 110, 210, 310 or 410 for example) is assembled, the assembled mirror blank is heated to fuse the components together. In some embodiments, a kiln or a similar apparatus is used to heat the mirror blank assembly although other apparatus and/or methods for heating may be used to hear the mirror blank assembly. In some embodiments, the mirror blank assembly is placed in or on a mold such as mold 50, as illustrated in FIG. 18. In particular, in some embodiments, when the mirror blank assembly is placed in or on mold 50, the opposing surface of primary glass (e.g. opposing surface 12 c of primary glass 12) is placed in contact with a mold surface 51 of mold 50. In some embodiments, mold 50 may comprise a spherical convex mold surface 51. In some embodiments, mold 50 may comprise a parabolic convex surface mold surface 51. Mold 50 (or at least mold surface 51) may be uniformly covered with a mold release agent prior to placing the mirror blank assembly in or on mold 50. The mold release agent may be sprayed on or applied such that mold surface 51 is coated with mold release agent. In some embodiments, the mold release agent may comprise aluminum powder or the like. If aluminum powder is applied, the aluminum powder may be allowed to harden. Mold 50, covered in aluminum powder, may be dried in a kiln. Mold surface 51 (with or without the mold release agent) should be relatively smooth (e.g. without significant indentations or bumps).

A mold together with the mirror blank assembly that is on or in the mold may together be placed in a kiln or the like for application of heat. The temperature of the kiln may raised to just below the molten temperature of glass (or some other suitable temperature) and the glass may be allowed to soak at this temperature. In some embodiments, this temperature is approximately 750° Celsius (+/−5%) and the mirror blank assembly is allowed to soak for 1-12 hours (e.g. approximately two hours) at this temperature. In some embodiments, the soaking time and temperature be different. While soaking, the contact surfaces of the individual components of the mirror blank assembly fuse together. In particular, abutment surfaces 16 a, 16 d of each of the plurality of splines 16 respectively fuse to primary planar surface 12 b of primary glass 12 and backing planar surface 14 b of backing glass 14. In some embodiments, the weight of the at least one of primary glass 12, backing glass 14 and glass splines 16 assists with the fusing of glass splines 16 to primary glass 12 and backing glass 14. In some embodiments, abutment surfaces 318 b, 318 c of a connector 318 may respectively fuse to primary planar surface 12 b of primary glass 12 and backing planar surface 14 b of backing glass 14. In some embodiments, surface 318 a of connector 318 may fuse to glass splines. In some embodiments, surfaces of braces 422, 422′ may similarly fuse to glass splines, to primary glass and/or to backing glass. While soaking, the primary glass may conform to mold surface 51 of mold 50 to take a shape complementary to the shape of mold surface 51. In particular embodiments, where mold surface 51 is spherically convex, primary glass takes a shape having a spherical concave curvature.

In some embodiments, mold 50 may be parabolic in shape and may produce parabolic mirror blanks. This may minimize the amount of grinding and polishing necessary to finish the mirror blank.

After soaking, the mirror blank (which is now monolithic (i.e. one-piece)) is allowed to cool naturally. Cooling naturally may comprise allowing the mirror blank to cool in an environment having an absence of temperature regulation or in an environment where the temperature is regulated to a constant (e.g. non-varying) temperature (e.g. room temperature in a thermostatically controlled room). Natural cooling is not necessary. In some embodiments, after soaking the mirror blank may be annealed in a process where the mirror blank is located in an environment where the temperature is actively regulated to match a specified temperature profile.

In some embodiments, during cooling, the mirror blank is arranged within a vessel having an insulating character (e.g. low thermal conductivity and/or high specific heat capacity) such as a kiln. In such embodiments, after soaking, the interior compartment of the vessel is at or near the soaking temperature (e.g. 750° Celsius) while the temperature of the environment exterior to the vessel may range between 5° and 50° Celsius. In some embodiments, the temperature of the environment exterior to the vessel is unregulated. In other embodiments, the temperature of the environment exterior to the vessel may be regulated to a constant temperature (e.g. room temperature in a thermostatically controlled room). In particular embodiments, the temperature exterior to the vessel may be regulated to a constant temperature of approximately 20° to 25° Celsius. The vessel, due to its insulating character, may slow down or otherwise retard the rate at which the mirror blank cools.

In some embodiments, the mirror blank is allowed to cool to the temperature of the environment exterior to the vessel while remaining within the vessel. In other embodiments, cooling naturally may comprise multiple cooling steps. In one particular embodiment, a first cooling step comprises allowing the mirror blank to cool while remaining in the closed vessel until a transition temperature is reached. A second cooling step may comprise opening the interior compartment of the vessel to be in fluid communication with the environment on an exterior of the vessel after the transition temperature is reached. In some embodiments, the transition temperature is approximately 110° Celsius (+/−5%), although this may vary in other embodiments. Cooling the mirror blank using multiple steps may shorten the length of time to cool the mirror blank. In particular, the first step may take approximately 24 hours while the second step may take approximately 4 hours.

After cooling, the resulting mirror blank may be removed from mold 50. Where mold surface 51 is spherically convex, the mirror blank will have a roughly spherically concave surface and negligible internal stress. In some embodiments, the concave surface of the mirror blank may require a grinding and/or polishing step to further shape the mirror blank. In some embodiments, the concave surface of the mirror blank may first be ground and/or polished into a substantially spherical shape, although this step is not necessary. In some embodiments, the concave surface of the mirror banks may be ground and/or polished into a parabolic shape (with or without first grinding and/or polishing the concave surface into a spherical shape). The grinding and polishing steps may require multiple iterations and testing to achieve the desired shape.

The finished mirror blank has a structure similar to the mirror blank assembly, except that the mirror blank is monolithic (e.g. one-piece). For example, if mirror blank assembly 10 is placed in mold 50 and heated to fuse together its components, the finished mirror blank will comprise a primary glass portion 12, a plurality of glass spline portions 16 and a backing glass portion 14.

Similarly, if assembled mirror blank assembly 110 is used, the resulting mirror blank will comprise a primary glass portion 112, a plurality of glass spline portions 116 and a backing glass portion 114. The mirror blank will additionally include backing opening 114 d. Backing opening may a circular perimeter having a center through which the axis of symmetry extends.

If assembled mirror blank 210 is used, the resulting mirror blank will comprise a primary glass portion 212, a plurality of glass spline portions 216 and a backing glass portion 214. The mirror blank will additionally include the primary opening 212 d and may or may not include backing opening 214 d. Primary opening 212 d may have a circular perimeter having a center through which the axis of symmetry extends.

If assembled mirror blank 310 is used, the resulting mirror blank will comprise a primary glass portion 312, a plurality of glass spline portions 316 and a backing glass portion 314. The mirror blank may include either or both of primary opening 312 d and backing opening 314 d and will additionally include a connector portion 318 or 320.

If assembled mirror blank 410 is used, the resulting mirror blank will comprise a primary glass portion 412, a plurality of glass spline portions 416 and a backing glass portion 414. The mirror blank may include any or all of primary opening 412 d, backing opening 414 d and connector portion 318 (or 320). The mirror blank will additionally include one or more brace portions 422.

The resulting mirror blank may share many other properties of the assembled mirror blank. The resulting mirror blank may have a plurality of spline portions having the same shape and size that extend in radial directions from an axis of symmetry of the resulting mirror blank. Spline portions may have equal angular spacing between circumferentially adjacent pairs of spline portions. The resulting mirror blank may have a primary circular perimeter having a diameter d₁ wherein a center of the primary circular perimeter intersects the axis of symmetry of the resulting mirror blank. The backing portion may have a backing circular perimeter wherein a center of the backing primary circular perimeter intersects the axis of symmetry of the resulting mirror blank.

The primary portion of the resulting mirror blank and the backing portion of the resulting mirror blank may have a spacing of approximately x, corresponding to a first height of the spline portions closest to the axis of symmetry. In some embodiments, the portions of the splines most distal from the axis of symmetry may have a height of approximately y, that is equal to or less than the first height x. For each spline portion, the first height of the spline portion may be in a range between ½ to 1/20 of the diameter d₁ of the primary portion of the resulting mirror blank. In other embodiments, for each spline portion, the first height of the spline portion is in a range between ⅙ to 1/10 of the diameter d₁ of the primary portion of the resulting mirror blank.

The resulting mirror blank, or any mirror blank based on assembled mirror blanks 10, 110, 210, 310 or 410 or a variation thereof will have a reduced weight as compared to a solid glass mirror blank. Furthermore, in some embodiments, the entire process described above, including preparation time (such as cutting, grinding and shaping of the individual components), assembling the mirror blank assembly, fusing and cooling may only take approximately 72 hours. Since the internal stresses are reduced, there are fewer chances of mirror blanks cracking. Accordingly, the process is less expensive and creates a product that is easier to install and allows for significant weight savings in making telescopes.

While a number of exemplary aspects and embodiments are discussed herein, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. For example:

-   -   Although only a few embodiments are depicted in the drawings, a         mirror blank assembly can include any combination of one or more         of a connector, glass braces, multi-layered round glass         segments, primary openings and backing openings in primary glass         and backing glass respectively.     -   Although the above method is described for creating a concave         mirror blank, a similar method could be used for forming a         convex mirror blank. Such a method would require a concave mold         and substantially similar mirror blank assemblies.

While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. 

What is claimed is:
 1. A method for manufacturing a mirror blank comprising: providing a primary piece of glass comprising a primary planar surface and a backing piece of glass comprising a backing planar surface; assembling a mirror blank assembly, wherein assembling the mirror blank assembly comprises interposing a plurality of glass splines between the primary glass and the backing glass, wherein interposing the plurality of glass splines comprises: for each glass spline, abutting a first surface of the glass spline against the primary planar surface of the primary glass and abutting a second surface of the glass spline, the second surface opposed to the first surface, against the backing planar surface of the backing glass; and arranging the plurality of glass splines to be circularly symmetric about an axis of symmetry that is orthogonal to the primary planar surface and the backing planar surface and to extend in directions that are radial from the axis of symmetry; wherein, for each glass spline, a dimension l₁ of the radial extension of the first surface which abuts the primary planar surface of the primary glass is greater than a dimension l₂ of the radial extension of the second surface which abuts the backing planar surface of the backing glass; and heating the mirror blank assembly to fuse the interposed glass splines to the primary glass and the backing glass while the primary glass and the secondary glass remain spaced apart from one another by the interposed glass splines to thereby provide the mirror blank.
 2. A method according to claim 1 wherein the primary glass, the backing glass and the glass splines have thermal coefficients that are the same +/−5%.
 3. A method according to claim 1 wherein the primary glass has a primary circular perimeter having a primary diameter d₁ and the backing glass has a backing circular perimeter having a backing diameter d₂ and d₁>d₂.
 4. A method according to claim 3 comprising aligning the primary glass and the backing glass so that the axis of symmetry intersects the center of the primary circular perimeter and the backing circular perimeter.
 5. A method according to claim 1 wherein each of the glass splines has a first height dimension x in a direction extending between the primary planar surface and the backing planar surface at a side of the glass spline closest to the axis of symmetry and a second height dimension y in the direction extending between the primary planar surface and the backing planar surface at a side of the glass spline most distal from the axis of symmetry and where y<x.
 6. A method according to claim 5 wherein the primary glass has a primary circular perimeter having a primary diameter d₁ and wherein, for each glass spline, the first height dimension x is in a range between ½ to 1/20 of the primary diameter d₁.
 7. A method according to claim 1 comprising shaping the primary glass to provide a primary opening therethrough.
 8. A method according to claim 7 comprising locating the primary glass such that the axis of symmetry extends through a center of the primary opening.
 9. A method according to claim 1 comprising shaping the backing glass to provide a backing opening therethrough.
 10. A method according to claim 9 comprising locating the backing glass such that the axis of symmetry extends through a center of the backing opening.
 11. A method according to claim 9 comprising shaping the primary glass to provide a primary opening therethrough.
 12. A method according to claim 1 wherein interposing the plurality of glass splines between the primary glass and the backing glass comprises spacing the glass splines about the axis of symmetry with equal angular spacing between circumferentially adjacent pairs of glass splines.
 13. A method according to claim 1 wherein interposing the plurality of glass splines between the primary glass and the backing glass comprises locating the plurality of glass splines such that portions of circumferentially adjacent glass splines closest to the axis of symmetry contact one another at locations spaced apart from the axis of symmetry.
 14. A method according to claim 1 wherein interposing the plurality of glass splines between the primary glass and the backing glass comprises locating the plurality of glass splines such that portions of the glass splines closest to the axis of symmetry are spaced apart from the axis of symmetry and from one another.
 15. A method according to claim 14 wherein locating the plurality of glass splines such that the portions of the glass splines closest to the axis of symmetry are spaced apart from the axis of symmetry comprises locating the plurality of glass splines such that the portions of the glass splines closest to the axis of symmetry are spaced apart from the axis of symmetry by a radial dimension that is the same for each glass spline.
 16. A method according to claim 14 wherein assembling the mirror blank assembly comprises interposing a glass connector between the primary glass and the backing glass, wherein interposing the glass connector between the primary glass and the backing glass comprising abutting a first surface of the glass connector against the primary planar surface of the primary glass and abutting a second surface of the glass connector against the backing planar surface of the backing glass and wherein heating the mirror blank assembly comprises heating the interposed glass connector and thereby fusing the glass connector to the primary glass and the backing glass.
 17. A method according to claim 16 comprising shaping the glass connector to define a bore therethrough and wherein interposing the glass connector between the primary glass and the backing glass comprises extending at least a portion of the bore between the primary planar surface of the primary glass and the backing planar surface of the backing glass.
 18. A method according to claim 17 comprising shaping the glass connector to define at least a portion of one or more venting apertures which permit fluid communication between the bore of the glass connector and a region outside of the bore of the glass connector when the glass connector is interposed between the primary glass and the backing glass.
 19. A method according to claim 18 wherein the one or more venting apertures are defined in part by at least one of the primary planar surface and the backing planar surface.
 20. A method according to claim 16 wherein the glass connector comprises a cylindrical outer surface and wherein interposing the glass connector between the primary glass and the backing glass comprises aligning the cylindrical axis with the axis of symmetry and, for each glass spline, abutting a surface of the glass spline closest to the axis of symmetry against the cylindrical outer surface of the glass connector.
 21. A method according to claim 20 wherein heating the interposed glass connector comprises fusing the cylindrical outer surface of the glass connector to the glass splines.
 22. A method according to claim 1 wherein assembling the mirror blank assembly comprises interposing a plurality of glass braces between the plurality of glass splines, wherein interposing the plurality of glass braces between the plurality of glass braces comprises, for each glass brace, abutting opposing surfaces of the glass brace against each of a corresponding pair of circumferentially adjacent glass splines.
 23. A method according to claim 22 wherein the glass braces are curved.
 24. A method according to claim 22 wherein the glass braces are generally straight and, for each glass brace, the opposing surfaces of the glass brace are bevelled with respect to the straight dimension of the glass brace.
 25. A method according to claim 22 wherein heating the mirror blank assembly comprises heating the interposed glass braces and thereby, for each glass brace, fusing the opposing surfaces of the glass brace to the corresponding pair of circumferentially adjacent glass splines.
 26. A method according to claim 25 wherein heating the mirror blank assembly comprises, for each glass brace, fusing the glass brace to the primary glass.
 27. A method according to claim 26 wherein heating the mirror blank assembly comprises, for each glass brace, fusing the glass brace to the backing glass.
 28. A method according to claim 1 wherein providing the primary piece of glass comprises abutting complementary surfaces of a pair of glass layers against one another, at least one of the complementary surfaces of the pair of glass layers comprising a plurality of channels, and wherein heating the mirror blank assembly comprises heating the pair of glass layers to fuse the complementary surfaces of the pair of glass layers to one another.
 29. A method according to claim 28 wherein at least one of the plurality of channels extends between peripheral edges of the at least one of the complementary surfaces of the pair of glass layers.
 30. A method according to claim 1 comprising, after heating the mirror blank assembly to fuse the interposed glass splines to the primary glass and the backing glass, cooling the mirror blank using a plurality of cooling steps, the plurality of cooling steps comprising: a first cooling step comprising allowing the mirror blank to cool in a first environment until the mirror blank reaches a set temperature; and a second cooling step comprising allowing the mirror blank to cool in a second environment until the mirror blank reaches an ambient temperature; wherein the first environment is regulated to have a decreasing temperature and the second environment is regulated to have a substantially constant temperature.
 31. A mirror blank fabricated according to the method of claim
 1. 32. A monolithic glass mirror blank comprising: a primary portion and a backing portion spaced apart from one another; and a plurality of spline portions extending between the primary portion and the backing portion; wherein, for each spline portion, a first surface of the spline portion is fused to the primary portion and a second surface of the spline portion, the second surface opposed to the first surface, is fused to the backing portion; wherein the plurality of spline portions are arranged to be circularly symmetric about an axis of symmetry and to extend in directions that are radial from the axis of symmetry; and wherein, for each spline portion, a dimension l₁ of the radial extension of the first surface which abuts the primary portion is greater than a dimension l₂ of the radial extension of the second surface which abuts the backing portion.
 33. A method for manufacturing a mirror blank assembly comprising: providing a primary piece of glass comprising a primary planar surface and a backing piece of glass comprising a backing planar surface; and assembling a mirror blank assembly, wherein assembling the mirror blank assembly comprises interposing a plurality of glass splines between the primary glass and the backing glass, wherein interposing the plurality of glass splines comprises: for each glass spline, abutting a first surface of the glass spline against the primary planar surface of the primary glass and abutting a second surface of the glass spline, the second surface opposed to the first surface, against the backing planar surface of the backing glass; and arranging the plurality of glass splines to be circularly symmetric about an axis of symmetry that is orthogonal to the primary planar surface and the backing planar surface and to extend in directions that are radial from the axis of symmetry; wherein, for each glass spline, a dimension l₁ of the radial extension of the first surface which abuts the primary planar surface of the primary glass is greater than a dimension l₂ of the radial extension of the second surface which abuts the backing planar surface of the backing glass. 